Central Hydraulics 7 Piece Porta Power Ram Kit 94681 Users Manual
2015-02-05
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7 Piece Porta-power Ram Kit 94681 Assembly And Operation Instructions Due to continuing improvements, actual product may differ slightly from the product described herein. ® 3491 Mission Oaks Blvd., Camarillo, CA 93011 Visit our website at: http://www.harborfreight.com To prevent serious injury, read and understand all warnings and instructions before use. Copyright© 2006 by Harbor Freight Tools®. All rights reserved. No portion of this manual or any artwork contained herein may be reproduced in any shape or form without the express written consent of Harbor Freight Tools. For technical questions or replacement parts, please call 1-800-444-3353. PRODUCT SPECIFICATIONS 2-Ton Hydraulic Push Ram (With Saddle) Height: 5.5” (Min.) / 9.5” (Max.) Operating PSI: 5700 / Maximum Capacity: 4400 lb. 1-5/8” Diameter 4-Ton Hydraulic Push Ram Height: 1.6” (Min.) / 2.2” (Max.) Operating PSI: 5700 / Maximum Capacity: 8800 lb. 2” Diameter 4-Ton Hydraulic Push Ram (With Spring) Height: 10.8” (Min.) / 16” (Max.) Operating PSI: 8000 / Maximum Capacity: 8800 lb. 1-5/8” Diameter 10-Ton Hydraulic Push Ram (With Saddle & Spring) Height: 5.2” (Min.) / 7.5” (Max.) Operating PSI: 8800 / Maximum Capacity: 22000 lb. 2-3/16” Diameter 10-Ton Hydraulic Push Ram (With Spring) Height: 13.7” (Min.) / 19.6” (Max.) Operating PSI: 8800 / Maximum Capacity: 22000 lb. 2-1/8” Diameter 2-Ton Hydraulic Pull Ram (With Spring) Height: 16.6” (Min.) / 21.6” (Max.) Operating PSI: 7800 / Maximum Capacity: 4400 lb. 1-1/2” Diameter 5-Ton Hydraulic Pull Ram (With Spring) Height: 20.4” (Min.) / 25.5” (Max.) Operating PSI: 8800 / Maximum Capacity: 11000 lb. 2-3/8” Diameter Accessories 2-Ton Pull Hooks (1 Set) / 5-Ton Pull Hooks (1 Set) / Metal Carrying Case Unit Weight 40 Pounds This equipment requires the addition of a Hydraulic Pump (such as Harbor Freight Sku 40611), hydraulic hoses, and hydraulic fittings to operate properly. None of this equipment is provided, and all of it must be properly rated for use with this kit. SAVE THIS MANUAL You will need this manual for the safety warnings and precautions, assembly, operating, inspection, maintenance and cleaning procedures, parts list and assembly diagram. Keep your invoice with this manual. Write the invoice number on the inside of the front cover. Keep this manual and invoice in a safe and dry place for future reference. UNPACKING When unpacking, check to make sure all the parts shown in the Parts Lists on pages 8 through 14 are included. If any parts are missing or broken, please call Harbor Freight Tools at the number shown on the front cover of this manual as soon as possible. GENERAL SAFETY RULES WARNING! READ AND UNDERSTAND ALL INSTRUCTIONS Failure to follow all instructions listed below may result in electric shock, fire, and/or serious injury. SAVE THESE INSTRUCTIONS SKU 94681 For technical questions, please call 1-800-444-3353. Page WORK AREA 1. Keep your work area clean and well lit. Cluttered and dark work areas invite accidents. 2. Keep bystanders, children, and visitors away while using this product. Distractions can cause you to lose control. PERSONAL SAFETY 1. Stay alert. Watch what you are doing, and use common sense during use. Do not use this product while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating power tools may result in serious personal injury. 2. Dress properly. Do not wear loose clothing or jewelry. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewelry, or long hair can be caught in moving parts. 3. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control in unexpected situations. 4. Always wear eye and hand protection. Wear ANSI-approved safety impact goggles, non-skid safety shoes, and heavy duty work gloves when using this product. TOOL USE AND CARE 1. Store idle tools and equipment out of reach of children and other untrained people. Tools and equipment are dangerous in the hands of untrained users. 2. Maintain this product with care. Keep this product clean. A properly maintained tool is easier to control. Do not use damaged tools and equipment. Tag damaged tools and equipment “Do not use” until repaired. 3. Check for misalignment or binding of moving parts, loose or broken parts, and any other condition that may affect this product’s operation. If damaged, have the tool serviced before using. Many accidents are caused by poorly maintained tools and equipment. 4. Use only accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one product may become hazardous when used on another product. SERVICE 1. Tool service must be performed only by qualified service technician. Service or maintenance performed by unqualified personnel could result in a risk of injury. SKU 94681 For technical questions, please call 1-800-444-3353. Page 2. When servicing this product, use only identical replacement parts. Follow instructions in the “Inspection, Maintenance, And Cleaning” section of this manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock or injury. SPECIFIC SAFETY RULES 1. WARNING! Do not exceed the maximum PSI capacity of each Hydraulic Ram in this Kit. Also, do not operate a Ram beyond its maximum range of travel. Exceeding the maximum PSI and travel capacity of a Ram can cause personal injury and/or property damage. IMPORTANT! Refer to the “Product Specifications” Table on page 2 of this manual to determine the maximum PSI and range of travel for each Hydraulic Ram included in this Kit. 2. Prior to using the Auto Body/Frame Repair Kit, make sure to read and understand all instructions and safety precautions as outlined in the auto manufacturer’s manual. Make sure the Auto Body/Frame Repair Kit is fully compatible with each specific vehicle. It is beyond the scope of this manual to discuss body/frame repair guidelines, and instead is the responsibility of the product user to consult a body/frame repair technical manual for full instructions. 3. Maintain labels and nameplates on the Auto Body/Frame Repair Kit. These carry important information. If unreadable or missing, contact Harbor Freight Tools for a replacement. 4. Use the right product for the job. There are certain applications for which this product was designed. Do not use this product for a purpose for which it was not intended. Never use this item to raise or move a vehicle. 5. Stay clear of an Hydraulic Ram when using the tool. Position your body as far away from the Ram as is practical when the Ram is under a load. It is possible for a Ram to slip under a load, possibly resulting in serious injury and/or property damage. 6. Industrial applications must follow OSHA requirements. 7. Before working on a vehicle, always set the parking brake and block the tires. Never attempt a repair while the engine is running or the vehicle is moving. 8. Avoid off-center loads. If the Hydraulic Pump (not included) unit seems unusually hard to pump, immediately stop the operation. Adjust the Hydraulic Ram unit to eliminate or diminish an off-center load. SKU 94681 For technical questions, please call 1-800-444-3353. Page 9. Keep the Hose Couplers protected when the Hydraulic Rams are not in use. Dust Caps are included for all Hose Couplers and should be screwed in when not in use to keep the internal mechanisms of the Rams clean. 10. WARNING! Prior to using the Auto Body/Frame Repair Kit, make sure to read and understand all instructions and safety precautions as outlined in the Hydraulic Pump (not included) manufacturer’s manual. 11. The results you achieve with these tools will depend upon your skills and experience at using tools of this type. Harbor Freight Tools is not responsible for damage to vehicles caused by misuse of these tools. 12. WARNING! This product will exert thousands of pounds of force when in use and can be dangerous. Use extreme caution when using this product. 13. Use compressed hydraulic fluid only. Do not use any other power source or fluid to operate this product. 14. WARNING! The warnings and cautions discussed in this manual cannot cover all possible conditions and situations that may occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. SAVE THESE INSTRUCTIONS TOOLS AND ACCESSORIES CARRYING CASE 5-TON PULL RAM WITH SPRING 4-TON PUSH RAM 2-TON PULL RAM WITH SPRING 4-TON PUSH RAM WITH SPRING 10-TON PUSH RAM WITH SADDLE & SPRING 2-TON PUSH RAM WITH SADDLE 10-TON PUSH RAM WITH SPRING FIGURE A SKU 94681 5-TON HOOKS 2-TON HOOKS For technical questions, please call 1-800-444-3353. Page Assembly instructions Refer to instructions provided with pump, hoses, and fittings for proper hydraulic line purging, preparation, and connection procedures. OPERATING INSTRUCTIONS WARNING! Before starting work, read and thoroughly understand all warnings and precautions in this manual and all documentation provided with the hydraulic pump and hoses used. Product Overview: The Auto Body/Frame Repair Kit is designed for bending frames and repairing dents in vehicle body panels. In most cases, the Push and Pull Hydraulic Rams in this Kit will only be capable of returning vehicle body and frame parts to their approximate, original position. Additional work may be required to completely repair the vehicle part. The Hydraulic Push Rams: 1. Included in this Kit are five Hydraulic Push Rams. The larger Push Rams are used in larger spaces where greater force is needed and where there is sufficient room to operate. The smaller Push Rams are used in tighter spaces where less force is required. (See Figure B.) 2. The Push Rams require a solid, non-movable base directly across from the damaged area and in line with the direction the damaged area needs to be bent. When positioning the Push Ram, place a block of wood or other material behind the base of the Push Ram and on the side that is to be bent for protection and to spread the Push Ram pressure over a greater area. (See Figure B.) CONNECT TO HYDRAULIC PUMP HOSE (NOT INCLUDED) WOOD BLOCK NON-MOVABLE AREA HERE HYDRAULIC PUSH RAM WOOD BLOCK DAMAGED AREA FIGURE B The Hydraulic Pull Rams: 1. Included in this Kit are two Hydraulic Pull Rams. The larger Pull Ram is used in larger spaces where greater force is needed and where there is sufficient room to operate. The smaller Pull Ram is used in tighter spaces where less force is required. (See Figure C, next page.) SKU 94681 For technical questions, please call 1-800-444-3353. Page 2. The Hydraulic Pull Rams may be used in either horizontal or vertical positions. The Hooks will turn to accept hooking from different angles. Hook one end of the Pull Ram to the object to be moved and the other end of the Pull Ram to a stable, unmovable base. A chain or strap may be used on either end to provide a hooking surface. Make sure the chain or strap is rated to support the pulling weight. (See Figure C.) HOOK TO CHAIN OR STRAP HOOK TO CHAIN OR STRAP HYDRAULIC PULL RAM CONNECT TO HYDRAULIC PUMP HOSE (NOT INCLUDED) FIGURE C HERE INSPECTION, MAINTENANCE, AND CLEANING 1. Before each use, inspect the general condition of the Auto Body/Frame Repair Kit. Check for bent, cracked, worn or damaged parts, loose or missing parts, and any other condition that may affect the Kit’s safe operation. If a problem occurs, have the problem corrected before further use. Do not use damaged equipment. 2. To clean, use a damp cloth and a mild detergent or mild solvent. Do not use flammable or corrosive agents. 3. When storing, keep the Auto Body/Frame Repair Kit in its Carrying Case and in a clean, dry, safe location out of reach of children and other unauthorized people. 4. CAUTION! All maintenance, service, and repairs not discussed in this manual should only be performed by a qualified service technician. TROUBLESHOOTING Problem Possible Cause Hydraulic Ram will not push or pull the load. Hydraulic Ram will push or pull, but will not maintain pressure. 1. Release Valve on Hydraulic Pump (not included) not tightly closed. 2. Overload condition. 2. Do not exceed maximum PSI or range of travel for Hydraulic Ram. 3. Air trapped in Hydraulic Pump system. 3. Purge air from Hydraulic Pump system. 4. Hydraulic Pump oil level low. 4. Add oil to proper level. 5. Loose connection from Hydraulic Pump to Hydraulic Ram. 5. Make sure connection from Hydraulic Pump to Hydraulic Ram is secure. 1. Release Valve on Hydraulic Pump (not included) not tightly closed. 1. Close Release Valve tightly. 2. Overload condition. 3. Hydraulic Pump or Hydraulic Ram malfunction. SKU 94681 Possible Solution 1. Close Release Valve tightly. 2. Do not exceed maximum PSI or range of travel for Hydraulic Ram. 3. Have a qualified service technician check out the Hydraulic Pump and/or Hydraulic Ram. For technical questions, please call 1-800-444-3353. Page PARTS LIST A - ASSEMBLY DIAGRAM A (2-TON HYDRAULIC PUSH RAM WITH SADDLE) Part Qty. Part Qty. Part 1A Nut Description 1 6A Cylinder Description 1 11A Connection Nut Description Qty. 1 2A Seal Ring 1 7A Spindle Screw 1 12A Hose Coupler 1 3A O-Ring 1 8A Spring 1 13A O-ring 1 4A Ram 1 9A Spindle 1 14A Dust Cap 1 5A O-Ring 1 10A Oil Ring 1 14A 12A 7A 3A 1A 13A 10A 11A 2A 4A 9A 8A 5A 6A NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISKS AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO. SKU 94681 For technical questions, please call 1-800-444-3353. Page PARTS LIST B - ASSEMBLY DIAGRAM B (4-TON HYDRAULIC PUSH RAM) Part Description Qty. Part Description Qty. Part Description Qty. 1B Nut 1 6B Cylinder 1 11B Connection Nut 1 2B Seal Ring 1 7B Spindle Screw 1 12B Hose Coupler 1 3B O-ring 1 8B Spring 1 13B O-ring 1 4B Ram 1 9B Spindle 1 14B Dust Cap 1 5B O-ring 1 10B Oil Ring 1 1B 2B 14B 3B 13B 4B 12B 11B 5B 10B 9B 6B 8B 7B NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 94681 For technical questions, please call 1-800-444-3353. Page PARTS LIST C - ASSEMBLY DIAGRAM C (4-TON HYDRAULIC PUSH RAM WITH SPRING) Part Qty. Part Qty. Part 1C Collar Description 1 8C Snap Ring Description 2 15C Cylinder Screw 1 2C Snap Ring 1 9C Spring 1 16C Thread Protector Ring 1 3C Piston Rod 1 10C Screw 1 17C Hose Coupler 1 4C Snap Ring 1 11C Cylinder Base 1 18C Dust Cover 1 5C Bushing 1 12C O-ring 1 19C Spring Pin 1 6C U-Cup 1 13C Cylinder 1 7C O-ring 1 14C Cylinder Collar 1 16C 15C Description Qty. 1C 2C 3C 14C 13C 4C 5C 6C 7C 8C 17C 18C 12C 11C 9C 19C 10C NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 94681 For technical questions, please call 1-800-444-3353. Page 10 PARTS LIST D - ASSEMBLY DIAGRAM D (10-TON HYDRAULIC PUSH RAM WITH SADDLE & SPRING) Part Qty. Part Qty. Part 1D Saddle Description 1 9D O-ring Description 1 17D Spring 1 2D Steel Sphere 1 10D Spring 1 18D Spindle 1 3D Spring 1 11D Nut 1 19D Oil Ring 1 4D Screw 1 12D Cylinder 1 20D Connection Nut 1 5D Ram 1 13D O-ring 1 21D Hose Coupler 1 6D Pin 1 14D Cover Nut 1 22D O-ring 1 7D Guiding Collar 1 15D Pin 1 23D Dust Cap 1 8D Cap (Nylon) 1 16D Spindle Screw 1 23D Description Qty. 1D 2D 22D 3D 21D 9D 20D 19D 4D 5D 12D 10D 6D 18D 17D 16D 11D 7D 13D 8D 15D 14D NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 94681 For technical questions, please call 1-800-444-3353. Page 11 PARTS LIST E - ASSEMBLY DIAGRAM E (10-TON HYDRAULIC PUSH RAM WITH SPRING) Part Qty. Part Qty. Part 1E Collar Description 1 8E Snap Ring Description 2 15E Cylinder Screw 1 2E Snap Ring 1 9E Spring 1 16E Thread Protector Ring 1 3E Piston Rod 1 10E Screw 1 17E Hose Coupler 1 4E Snap Ring 1 11E Cylinder Base 1 18E Dust Cover 1 5E Bushing 2 12E O-ring 1 19E Spring Pin 1 6E U-Cup 1 13E Cylinder 1 7E O-ring 1 14E Cylinder Collar 1 16E 15E Description Qty. 1E 2E 3E 14E 13E 4E 5E 6E 7E 17E 18E 8E 12E 9E 19E 11E 10E NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 94681 For technical questions, please call 1-800-444-3353. Page 12 PARTS LIST F - ASSEMBLY DIAGRAM F (2-TON HYDRAULIC PULL RAM WITH SPRING) Part Qty. Part Qty. Part 1F Hook Description 2 11F O-ring Description 1 21F Nut Description Qty. 1 2F Axle Pin 2 12F U-Type Packing 1 22F Screw Coupler 1 3F Coupling 2 13F Guiding Collar 1 23F Spindle Screw 1 4F Collar 2 14F Nut 1 24F Spring 1 5F Split Pin 2 15F Spring 1 25F Spindle 1 6F Nut 1 16F Shaft 1 26F Oil Ring 1 7F Screw 1 17F O-ring 2 27F Connection Nut 1 8F Ram 1 18F Nut 1 28F Hose Coupler 1 9F Closing Ring 2 19F O-ring 1 29F O-ring 1 10F Carrier Ring 1 20F Cylinder 1 30F Dust Cap 1 1F 11F 21F 12F 22F 16F 2F 4F 5F 13F 14F 3F 6F 7F 1F 17F 18F 8F 19F 15F 30F 29F 28F 27F 26F 20F 9F 10F 25F 24F 23F NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 94681 For technical questions, please call 1-800-444-3353. Page 13 PARTS LIST G - ASSEMBLY DIAGRAM G (5-TON HYDRAULIC PULL RAM WITH SPRING) Part Qty. Part Qty. Part 1G Top Hook Description 1 10G Nut Description 1 19G Spring Description Qty. 1 2G Nut 1 11G Spring 1 20G Spindle 1 3G Hex Screw 1 12G Shaft 1 21G Oil Ring 1 4G Ram 1 13G O-ring 2 22G Connection Nut 1 5G Bushing 1 14G Nut 1 23G Hose Coupler 1 6G Closing Ring 2 15G O-ring 1 24G O-ring 1 7G O-ring 1 16G Cylinder 1 25G Dust Cap 1 8G U-Type Packing 1 17G Bottom Hook 1 9G Collar 1 18G Spindle Screw 1 1G 25G 24G 23G 22G 21G 20G 19G 18G 13G 2G 3G 14G 4G 15G 11G 16G 5G 6G 7G 17G 8G 12G 9G 10G NOTE: Some parts are listed and shown for illustration purposes only, and are not available individually as replacement parts. SKU 94681 For technical questions, please call 1-800-444-3353. Page 14 Limited 90 day warranty Harbor Freight Tools Co. makes every effort to assure that its products meet high quality and durability standards, and warrants to the original purchaser that this product is free from defects in materials and workmanship for the period of ninety days from the date of purchase. This warranty does not apply to damage due directly or indirectly, to misuse, abuse, negligence or accidents, repairs or alterations outside our facilities, or to lack of maintenance. We shall in no event be liable for death, injuries to persons or property, or for incidental, contingent, special or consequential damages arising from the use of our product. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you. This warranty is expressly in lieu of all other warranties, express or implied, including the warranties of merchantability and fitness. To take advantage of this warranty, the product or part must be returned to us with transportation charges prepaid. Proof of purchase date and an explanation of the complaint must accompany the merchandise. If our inspection verifies the defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily and quickly provide you with a replacement. We will return repaired products at our expense, but if we determine there is no defect, or that the defect resulted from causes not within the scope of our warranty, then you must bear the cost of returning the product. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. 3491 Mission Oaks Blvd. • PO Box 6009 • Camarillo, CA 93011 • (800) 444-3353 SKU 94681 For technical questions, please call 1-800-444-3353. Page 15
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